Sloss Furnaces National Historic Landmark Teacher`s Handbook

Sloss Furnaces National
Historic Landmark
Teacher’s Handbook
2
Teacher’s Handbook
Introduction
3-4
The Story of Sloss Furnaces
5-6
Sloss Company Timeline
7
Science Behind Sloss
8-9
Sloss and its Minerals
10
Recycling at Sloss Past and Present
11-12
Touring Sloss Furnaces & Activities
13—20
History
of Sloss
Furnaces
Teacher’s
Handbook
3
This handbook offers an abundance of information about Sloss Furnaces National
Historic Landmark and the ironmaking process.
Sloss Furnaces is Birmingham’s museum of industrial history. The focus of the museum
is a group of structures comprising the Sloss-Sheffield Steel and Iron Company’s City Furnaces
that produced pig iron from 1882 to 1970. The site has been formally recognized as a National
Historic Landmark, reflecting the national significance of the complex’s structures.
The purpose of the Sloss Furnace Museum is four-fold:
1.to act as a cultural resource by being a center for community events, civic life
and for the creation, display, and interpretation of metal art.
2.To preserve the physical facility as an historic landmark and museum.
3.To collect objects and documents to increase understanding of Birmingham’s
historic industrial technology and culture.
4.Interpret the historic, cultural and technological aspects of the facility.
THIS MATERIAL IS DESIGNED TO FAMILIARIZE EDUCATORS AND THEIR STUDENTS WITH
SLOSS FURNACES NATIONAL HISTORIC LANDMARK. IT GIVES INFORMATION TO HELP
MEET TEACHING OBJECTIVES FOR K-12 STUDENTS.
THE MUSEUM OFFERS A UNIQUE SETTING FOR STUDY OF A WIDE RANGE OF SUBJECTS.
THE OLD IRONMAKING SITE AFFORDS THE OPORTUNITY FOR STUDY OF SOCIAL
HISTORY, CHEMISTRY, GEOLOGY, TECNOLOGY, PHYSICS, AND NATURAL HISTORY AND
MANY OTHER SUBJECTS. TO FULLY EXPLORE THE SITE’S EDUCATIONAL POTENTIAL, WE
SUGGEST COMBINING THE INFORMAITON INCLUDED IN THE HANDBOOK WITH A GUIDED
TOUR OF THE LANDMARK
Just east of downtown Birmingham, the entrance to Sloss Furnaces National Historic
Landmark is located at 32nd Street and 2nd Avenue, North. The museum’s administrative staff
is on site Monday through Friday from 8:00a.m. to 4:00p.m. Special community events at Sloss
often take place after hours and on the weekends.
4
Mailing Address:
Sloss Furnaces National Historic Landmark
Twenty 32nd Street North
Birmingham, AL 35222
Telephone:
(205) 324-1911
Website:
www.slossfurnaces.com
Hours of Operation:
Tuesday-Saturday: 10 a.m. to 4 p.m.
Sunday: 12 p.m. to 4 p.m.
Monday: Closed to Public
Fax: (205) 324-6758
The Sloss Furnaces have graced the Birmingham skyline for more than a century. For almost
ninety of those years, the furnaces produced pig iron, iron that fed the city’s hungry foundries
and steel mills. People once gathered in the smoke and fumes along the streets near Sloss to
watch the molten iron and burning slag pour from the furnaces that filled the sky with a fiery
orange glow. The collective memory of Birmingham is filled with stories of furnaces belching
smoke and fire and of men who lived with the intense heat and back breaking labor.
These days, Sloss tells a different kind of story. The furnaces were closed in 1971, lost to
obsolescence and declining markets for pig iron. But this was not the end. The towering furnaces and stoves, the huge old steam engines, have been preserved as an unusual new
museum, one that tells the story of the dreams and sweat that built a “Magic City.”
History of Sloss Furnaces
5
In 1876 a young railroad man from northern Alabama rode into Birmingham. The city was no
industrial giant in those days, just a rowdy little town at the foot of Red Mountain, dotted with
pine shacks and muddy roads. But Birmingham was destined to grow. The discovery of iron
ore, coal, and limestone—all of the ingredients needed to make iron and all within a 4-mile
radius—made the land rich beyond measure. It was the age of industrialization and iron was
transforming America into a modern society. Iron railways carried iron locomotives across the
continent and opened new lands for development. Iron steamships crossed the Atlantic, bringing millions of immigrants to live and work in the new world. The men who worked in the blast
furnaces, rolling mills and foundries were making the iron to build a nation.
The young railroad man, Colonel James Withers Sloss, had a knack for turning ideas into businesses that made money. He also had a dream. Anxious to develop the Birmingham district as
an iron making center, he invested heavily in railroads, coal mines,
and blast furnaces. He founded the Sloss Furnace Company in 1881
and a year later completed two blast furnaces on the eastern edge of
the new city. The Sloss Furnaces soon were matched by other furnaces and as word of Birmingham’s ironmaking potential spread,
money flowed in to build still more.
Birmingham’s burgeoning iron and steel industries drew thousands of settlers into the area.
Families moved in from the surrounding countryside, leaving farm communities likes Hoke’s
Bluff and Slap Out, to take jobs in the coal mines or the city’s pipe plants and rolling mills. Others came from England, Scotland, Wales, Greece, Italy, and Lebanon to name a few. Those
who did not work in the iron and steel industries opened grocery and dry goods stores or other
businesses to serve those who did.
As Birmingham flourished, so did Sloss. The colonel retired in 1886 and sold the company to a
group of Virginian financiers who guided it through a period of rapid growth. With the acquisition of extensive ore and coal lands and several furnaces in northern Alabama, the company
became the second largest in the Birmingham district. The Sloss Furnaces, oldest of the company’s holdings, were rebuilt during this period and several massive stoves and boilers were
added. Then, in the late 1920s, as the company approached its 50th birthday, those furnaces
were replaced with two new ones, each equipped with modern machinery to do some of the work once done by men and mules. The
furnaces still ran day and night. And they created a fiery spectacle
at each pour of iron. But now, they had almost doubled their earlier
capacity, each producing 400 tons of iron a day, day after day.
6
Sloss Furnaces changed hands a number of times over the years. U.S. Pipe and Foundry, a Jim
Walter Company, closed the furnaces in 1971. The company recognized the historic character
of the old ironmaking plant however, and donated the Sloss property to the people of Birmingham. Ideas for using the site varied wildly, ranging from proposals to convert the furnaces into
a Disney-like theme park to more modest visions of an industrial museum. Nobody could reach
a decision. The furnaces stood neglected for years, until finally damage was so heavy that officials recommended they be torn down.
The threatened demolition of Sloss rallied Birmingham citizens to save the old furnaces. Why
save Sloss? As one proponent said, “A lot more than iron flowed from those furnaces. Our
whole culture did, a whole way of life.” Another supporter put it this way:
“Sloss reminds us that Birmingham exists because it was here that everything
came together—the railroads, the raw materials, and the men with the genius
to make it all work.” Birmingham voters agreed and in 1977 they approved
funds to preserve the historic landmark.
Many things has happened since then. Sloss has been recognized as one of the most important
industrial historic preservation projects in the United States. The U. S. Department of the Interior, acknowledging the national significance of the site, named Sloss a National Historic Landmark in 1981. Workers have sandblasted, patched and painted, renewing the historic structures, but not changing them. And that’s important, because Sloss looks like what it was—a
place where men worked.
In 1983 Sloss opened its gates to the public as a museum of history and industry.
With its massive buildings and web of pipes, its tall, slender smokestacks, Sloss
forms a powerful connection to the city’s past. Here, history is more than facts
and figures, it’s something you can touch and smell. Guided tours give visitors an
opportunity to explore the furnaces and experience the power and drama of modern industry. Special programs and exhibits turn old photographs, documents,
and artifacts into stories about a city fashioned from mines and mills, furnaces and
foundries. Yet Sloss is more than just a museum. It is a unique urban center, a quiet place near
the heart of the city, where friends can meet for lunch or enjoy a walk. Sloss is also a performing arts center. In the giant East Cast Shed, where molten iron once was cast into ingots called
pigs, a dramatic stage hosts symphonies and jazz bands, dancers and musicians, and also
weddings and parties. Iron still flows from the West Cast Shed where the internationally recognized Metal Arts Program is housed. For informal events a smaller stage is nestled at the foot
of the giant Sloss water tower.
Sloss Furnaces National Historic Landmark is an authentic symbol of Birmingham. Museum,
performing arts center, meeting place...the furnaces represent the true character and spirit of
the city. Sloss is alive again. Not making iron anymore, but still making magic.
Sloss Company History Timeline
7
The Sloss Furnace Company organized and established by Colonel James Withers
Sloss. The first furnace blown in on April 12, 1882, followed by the second furnace
approximately one year later.
1886-1887 The company sold to John W. Johnston, president of the Georgia Pacific Railroad,
and Joseph F. Johnston, president of the Alabama National Bank. Company
changed to the Sloss Iron and Steel Company.
1887-1889 Two additional blast furnaces built in North Birmingham.
1891
Sloss began using convict labor only in its coal mines, and continued the practice
until it was legally abolished in 1929.
1894
Sloss iron exported for the first time; 100 tons shipped to Liverpool via the port of
New Orleans.
1898-1899 Sloss bought out twelve smaller companies and in the process acquired three
blast furnaces in the Florence-Sheffield District, coal lands in Walker County, and
ore lands in Franklin County. The company reorganized as the Sloss-Sheffield
Steel and Iron Company, incorporated in New Jersey in 1899.
1902-1919 City Furnaces and North Birmingham Furnaces rebuilt, new blowing engine house
built (still standing), Rust boilers built (still standing), additional stoves built.
1918-1920 A modern coke by-products plant built in North Birmingham. 1380 beehive coke
ovens replaced by 120 Semet-Solvey and 30 Koppers by-products ovens.
1923-1924 Sloss acquired the Sheffield Iron Corporation, with one furnace in Sheffield, and
the Alabama Company, with two furnaces at Gadsden, and two at Ironaton, near
Talladega.
1926-1928 Sloss closed all its north Alabama furnaces, and concentrated efforts on the two
City Furnaces and the two North Birmingham Furnaces. The City Furnaces totally
rebuilt, doubling their capacity, and the North Birmingham Furnaces improved. A
pig casting machine from Gadsden installed at North Birmingham.
1931
Pig casting machine installed at the City Furnaces.
Late 1940s Slag granulators installed.
1949-1951 Turbo blowers installed, replacing the reciprocating steam blowing engines.
1952
Sloss-Sheffield Steel and Iron Co. merged with U.S. Pipe Corporation.
1952-1958 The capacity of the North Birmingham coke works doubled.
Late 50s-60s North Birmingham Furnaces dismantled. Sloss began importing ores and discon
tinued mining operations on Red Mountain and at Russellville.
1969
The Jim Walter Corporation acquired control of U.S. Pipe.
1971
Sloss City Furnaces closed due to technological obsolescence, declining market
for pig iron, and high cost of installing pollution control equipment. Furnace site
donated to the Alabama State Fair Authority.
1974
Sloss Furnaces entered into the National Register of Historic Places. Bonds issued
to convert the furnaces into an industrial museum.
1981
Sloss Furnaces designated a National Historic Landmark by the United States
Department of the Interior.
1983
Labor Day, September 5th, Sloss Furnaces National Historic Landmark opened to
the public.
1881-1883
The Science Behind Sloss Furnaces
8
Pig iron was made by melting iron ore in furnaces fired with coke (coal processed to produce
extreme heat) and vast quantities of heated air. Molten iron separated from its ore's impurities and
sank to the bottom of the furnace. The lighter waste material, combining with molten limestone,
formed slag which floated above the iron. While slag was tapped every two hours, the liquid iron
was tapped every four hours and run into the cast shed. Prior to the exclusive use of the pig casting
machine, molten iron flowed down hand-formed sand channels into small sand molds. The resulting
shape resembled piglets suckling a sow, hence the name "pig iron."
BLAST
FURNACE
The blast furnace is the core of the iron-making operation. Within the furnace iron ore, flux
(limestone, dolomite, or a combination of the two), coke (processed coal), and hot air combine to
produce pure molten iron and two waste products: molten slag and exhaust gas. The molten products collect in the bottom of the furnace and are drained off periodically. The gas leaves the furnace
through the top and is routed to fuel the blast stoves and power boilers.
Sloss Furnaces consisted of two furnaces, known as No. 1 and No. 2. The original furnaces
were built between 1881 and 1883 and operated until 1927 when they were replaced by the furnaces that stand today. From each furnace extends a long, open building called the cast shed, in
which the molten iron was cast into bars, or "pigs."
The blast furnace worked 24 hours a day, seven days a week, so it was continually being
charged with raw materials and drained of its molten products. New materials were added at the
same rate at which iron and slag were produced. Iron ore, flux, and coke were charged into the
top, through a stock channel just six feet above the blast, while hot air was blown into the bottom
through openings called tuyeres (pronounced "tweers"). The hot air fueled the burning coke which
released both carbon monoxide, C + O2 à CO, and an extreme amount of heat (over 2000 degrees
Fahrenheit) which swept upward, heating the slowly descending stock. The carbon monoxide, hungry for oxygen atoms, drew them away from the molten ore, forming carbon dioxide and freeing
pure iron.
Fe2O3 + CO à FeO
+ CO2
The freed iron condensed and pooled in the hearth. Meanwhile, the flux soaked up the remaining byproducts (ore impurities and coke ash) to form slag. The slag ran into the hearth and
floated on top of the molten iron. About every four hours workers tapped the furnace to remove the
iron accumulated in the hearth. Iron was drained through the iron notch, a hole at the base of the
furnace that was kept plugged with fireclay. A crew of workers drilled a hole through the clay, releasing the iron. Originally, the iron ran from the notch down hand-cut channels in the sand of the
cast-shed floor and into hand-cut pig-molds, but later the molten product traveled down a curved
runner and into a ladle car, which transported the iron to a pig casting machine. When the cast leveled, the notch was replugged with clay using a "mud gun." The slag was drained through a separate runner.
9
Sloss Furnaces and its Minerals
Iron Ore
Coke (processed coal)
10
Limestone
Birmingham was founded in 1871 and its heritage is closely connected to the iron and steel
industry. Because of the unique geology of the area, all the raw materials need to make iron—
iron ore, coal, and limestone—are all found within a few miles of each other. This is the only
place in the entire country that you can find this certain geological formation. So it was the minerals beneath the ground that enticed the city’s founders to Jones Valley—eventually the city
of Birmingham.
This unique geological formation existed millions of years before its industrial importance was
realized. This formation began in the Paleozoic Era. In the earliest of the Paleozoic Era’s seven
periods, the Cambrian, which began 570 million years ago, an enormous shallow sea stretched
across what is now Alabama. Sediments from a northwest area and volcanic debris from the
islands to the southeast accumulated and caused the floor of the sea to sink. Then, in the
Ordovician Period, 500 to 440 million years ago, these deposits changed into limestone and
dolomite. During the Silurian Period, 440 to 400 million years ago, enormous amounts of iron
were deposited into the same inland sea. By the Pennsylvanian Period, beginning 320 million
years ago, much of the sea had turned into swamps. The swamps and sea teemed with plant
and animal life, whose remains decayed and accumulated for many eons. The accumulation
began a process where in the remains became weighty, causing heat and pressure that
changed the remains into large amounts of peat, lignite, and bituminous coal.
Toward the end of the Paleozoic Era, about 280 million years ago, the earth itself groaned and
roared. The tectonic plates that form the base of the North American and African continents
had been drifting towards each other and finally collided. This collision heaved up deposits and
caused them to fold and buckle eventually forming Red Mountain and Jones Valley. It was the
formation of Red Mountain that made the mineral wealth within accessible to miners millions of
years later.
Recycling at Sloss: The Past
11
To put it simply, Sloss did not waste a single thing. The ironmaking process crates various
waste products and gases that can be used to make other products. The best example of a
waste product at Sloss is Slag. As mentioned previously, the flux (or limestone) soaked up the
remaining by-products (ore impurities and coke ash) to form slag.
The slag would be released from the furnaces about every 2 hours. It would flow into the slag
pit for cooling or it would be sent through the granulator to be crushed into smaller pieces.
Once the slag cooled, companies would purchase slag from Sloss and renew this waste. Sloss
also used slag and other waste gasses in its by-products plant to make products as well.
Slag can be used in a number of ways. Sloss used it to make concrete, but it can also be used
to make cinder blocks, railroad bedding, road bedding, insulation, cement, dry wall, and fire
proofing materials.
Other products were also made from waste gases produced in the ironmaking process. See
the following Sloss product advertisements:
Recycling at Sloss: The Present
12
Although Sloss’s furnaces sit quietly overlooking the Birmingham skyline today, Sloss continues to recycle. New furnaces, called cupolas, are now alive and carrying on Sloss’s ironmaking tradition of old. The No. 2 casting shed on the west end of the site is home to the innovative and nationally recognized Sloss Metal Arts Program. The cupolas are vastly
smaller and cannot produce large amounts of waste like the furnaces once did in the past.
Therefore, recycling at Sloss is much different today. The Sloss Metal Artists recycle old
radiators, tire drums, and other scrap metal to make it into works of cast iron art. The process is much the same. The artists use scrap iron, coke, and a few pieces of limestone along
with a hot blast of air. The furnaces heat to approximately 3000ºF and is tapped every 10 to
45 minutes depending on the size of the cupola being used. The artists pour the molten iron
into sand molds they design. Once the iron is cooled, the molds are opened. Something that
was once discarded scrap iron is transformed into a beautiful and unique piece of metal art!
Touring Sloss Furnaces
13
Tour Options
Guided Walking Tour: Come learn about the history of Birmingham in a fun way; learn about its
rocks and minerals, men and machinery. Walk through the underground railroad tunnel, blowing engine room, see the furnace and bring a brown-bag lunch to eat by the spray pond. Lasts
approximately 1 hour; costs $2 per person (teachers are free).
Guided Tour + Iron Pour: See molten iron poured into a mold you design! Feel, hear, and smell
the heat! Experience what Sloss was like years ago. Take home a cast-iron tile souvenir you
designed and created. Kids of all ages love this! After the walking tour and iron pour, have
lunch by the spray pond. Lasts approximately 2 hours; costs $16 per student/ $5 per
chaperone
Tour Reservations
Contact Sloss Furnaces Education Coordinator, Heather Guy, for tour reservations or information at 205.324.1911 or hguy@slossfurnaces.com.
Guided tours are available to groups by appointment. Reservations for group tours should be
made at least two weeks in advance. To schedule a guided walking tour or iron pour + walking
tour, please have the following information (there is a 15 person minimum):
* Requested Tour Date/ Time (if you are scheduling an iron pour + tour, please note that
we have pre-arranged dates and you must choose from those)
* Organization/ School
* Leader/ Teacher
* Email Address/ Telephone Number
* Age/ Grade Level
* Approximate Number In Group
* Special Requirements/ Interests
Should any changes occur, please let us know as soon as possible so adjustments can be
made.
Tours also include a 15 minute film. If necessary, the tour route can be abbreviated.
Because much of the facility is outdoors, tour groups will need to come prepared for outside
weather conditions. Close toed shoes are preferred. In the case of inclement weather, the tour
may be rescheduled.
Activities
The Process of Making Pig Iron
Directions: Read the information below (take notes on each paragraph), the recipe for
pig iron on the next page, and the diagram of the furnace on the next page. Then, answer the questions that follows.
Pig iron was made by melting iron ore in furnaces fired with coke (coal processed to produce extreme heat) and large quantities of heated air. Molten iron separated from its ore's impurities and sank to the bottom of the furnace. The lighter waste
material, combining with molten limestone, formed slag which floated above the iron.
While slag was tapped every two hours, the liquid iron was tapped every four hours and
run into the cast shed. Prior to the exclusive use of the pig casting machine, molten iron
flowed down hand-formed sand channels into small sand molds. The resulting shape
resembled piglets suckling a sow, hence the name "pig iron". Sloss Furnaces consisted of two furnaces, known as No. 1 and No. 2. The original furnaces were built between 1881 and 1883 and operated until about 1920 when they were replaced by the
furnaces that stand today. From each furnace extends a long, open building called the
cast shed, in which the molten iron was cast into bars, or "pigs."
The blast furnace is the core of the iron-making operation. Within the furnace
iron ore, flux (limestone, dolomite, or a combination of the two), coke (processed coal),
and hot air combine to produce pure molten iron and two waste products: molten slag
and exhaust gas. The molten products collect in the bottom of the furnace and are
drained off periodically. The gas leaves the furnace through the top and is routed to
fuel the blast stoves and power boilers. The blast furnace worked 24 hours a day,
seven days a week, so it was continually being charged with raw materials and drained
of its molten products. New materials were added at the same rate at which iron and
slag were produced. About every four hours workers tapped the furnace to remove the
iron accumulated in the hearth. Iron was drained through the iron notch, a hole at the
base of the furnace that was kept plugged with fireclay. A crew of workers drilled a
hole through the clay, releasing the iron.
Casting is the shaping of molten iron, and the technology of casting this iron into bars,
called "pigs," has changed dramatically over the years. Prior to 1931, casting at Sloss
took place inside the cast shed. Men cut molds and channels into the sand floor of the
shed, and then tapped the molten iron to pour through the channels and into the individual molds. Because many ironworkers thought the configuration of molds feeding off
troughs resembled an arrangement of pigs feeding at a sow, they called the iron bars
"pigs."
QUESTIONS:
1. What are the five ingredients for making Pig Iron?
2. Where did “pig iron” get its name?
3. What phases of matter are involved in the process of making iron?
4. What is the melting point of iron ore?
5. After the iron is created, what happens to the impurities?
6. Describe casting.
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SLOSS FURNACES WORD SEARCH
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WORD LIST
BLAST FURNACE
FOUNDRY
PIG IRON
BLOWERS
HOT BLAST STOVES
POWER HOUSE
BLOWING ENGINE
IRON ORE
PYROMETER HOUSE
BOILERS
JAMES WITHERS SLOSS
SLAG
CAST SHED
LADLE CAR
STEAM
COAL
LIMESTONE
TAP
COKE
METAL ART
TRESTLE
COOLING POND
PIG CASTER
THE MAGIC CITY
16
THE SLOSS SCRAMBLE
These are words associated with Sloss Furnaces National Historic Landmark.
hte agimc itcy
scta edhs
deall arc
boignwl innege
loca
cloogin ndop
ipg onri
sajem ihwrets sssol
etesnmoli
amlet rat
eblsori
oth btlas svesot
emast
slga
roin oer
sssol ucfnares
oiesrbl
batsl crenuaf
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SLOSS FURNACES WORD SEARCH
PRE K-5
TEST YOUR CAST IRON SKILLS!!
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WORD LIST
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FURNACE
MAGIC CITY
SLAG
PIG IRON
LIMESTONE
COAL
IRON ORE
18
19
20